U.S. patent application number 17/627198 was filed with the patent office on 2022-08-18 for system and method for manufacturing panels for use in wind turbine rotor blade components.
The applicant listed for this patent is General Electric Company. Invention is credited to Huijuan Dai, Andrew McCalip, Collin McKee Sheppard, James Robert Tobin, Lauren Laurer Watts, Hongyi Zhou.
Application Number | 20220260050 17/627198 |
Document ID | / |
Family ID | |
Filed Date | 2022-08-18 |
United States Patent
Application |
20220260050 |
Kind Code |
A1 |
Tobin; James Robert ; et
al. |
August 18, 2022 |
SYSTEM AND METHOD FOR MANUFACTURING PANELS FOR USE IN WIND TURBINE
ROTOR BLADE COMPONENTS
Abstract
A system for manufacturing a panel includes a support frame, a
first caul plate arranged atop the support frame, a second caul
plate arranged atop the first caul plate, and a heating assembly
having a housing defining an inlet and an outlet. The housing
includes one or more heaters. The heater(s) is configured to
generate heat and the housing is configured to generate a first
pressurized gas film. Thus, one or more layers of material to be
consolidated may be placed between the first and second caul plates
and drawn through the heating assembly as the heating assembly
applies pressure to the one or more layers of material to be
consolidated via the first pressurized gas film in combination with
applying the heat via the one or more heaters, thereby
consolidating the panel.
Inventors: |
Tobin; James Robert;
(Greenville, SC) ; McCalip; Andrew; (Houston,
TX) ; Watts; Lauren Laurer; (Lyman, SC) ;
Zhou; Hongyi; (Schenectady, NY) ; Dai; Huijuan;
(Simpsonville, SC) ; Sheppard; Collin McKee;
(Greenville, SC) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
General Electric Company |
Schenectady |
NY |
US |
|
|
Appl. No.: |
17/627198 |
Filed: |
July 16, 2019 |
PCT Filed: |
July 16, 2019 |
PCT NO: |
PCT/US2019/041905 |
371 Date: |
January 14, 2022 |
International
Class: |
F03D 1/06 20060101
F03D001/06; B29C 43/36 20060101 B29C043/36; B29C 43/52 20060101
B29C043/52; B29C 70/52 20060101 B29C070/52 |
Claims
1. A system for manufacturing a panel, the system comprising: a
support frame; a first caul plate arranged atop the support frame;
a second caul plate arranged atop the first caul plate; and, a
heating assembly comprising a housing defining an inlet and an
outlet, the housing comprising one or more heaters, the one or more
heaters configured to generate heat, the housing configured to
generate a first pressurized gas film; wherein one or more layers
of material to be consolidated is placed between the first and
second caul plates and drawn through the heating assembly as the
heating assembly applies pressure to the one or more layers of
material to be consolidated via the first pressurized gas film in
combination with applying heat via the one or more heaters, thereby
consolidating the panel.
2. The system of claim 1, further comprising a cooling assembly
consecutively aligned with the heating assembly for solidifying the
panel.
3. The system of claim 2, wherein the heating assembly further
comprises at least one optical window arranged adjacent to the one
or more heaters, the heat from the one or more heaters passing
through the at least one optical window and heating the one or more
layers of material to be consolidated.
4. The system of claim 2, wherein the cooling assembly is
configured to apply a second pressurized gas film to the panel
while a chilled air stream is circulated over the panel.
5. The system of claim 1, wherein the one or more heaters further
comprises a plurality of first heaters and a plurality of second
heaters, the plurality of first heaters arranged below the first
caul plate, the plurality of second heaters arranged above the
second caul plate.
6. The system of claim 1, wherein the heating assembly further
comprises one or more sealing members between the housing and the
first and second caul plates, the one or more sealing members
providing a sealed environment that maintains a desired pressure
between the housing and the first and second caul plates.
7. The system of claim 6, wherein the one or more sealing members
comprise a first sealing ring and a second sealing ring between the
housing and the first and second caul plates.
8. The system of claim 6, wherein the one or more sealing members
comprise variable height seals, wherein the one or more layers of
material to be consolidated further comprises one or more fiber
and/or resin layers having a variable thickness, the variable
height seals accommodating the variable thickness.
9. The system of claim 2, wherein the one or more heaters comprise
at least one of radiant heaters or lasers.
10. The system of claim 1, further comprising a spool, wherein,
upon cooling, the panel is separated from the first and second caul
plates and spooled onto the spool.
11. The system of claim 10, wherein the first and second caul
plates are hinged on one side thereof to facilitate removal of the
panel and reinserting one or more additional layers of material to
be consolidated layers to for repeat processes.
12. The system of claim 1, wherein the first and second caul plates
are constructed of at least one of steel or titanium.
13. The system of claim 2, wherein the first and second caul plates
are continuous belts that rotate through the heating and cooling
assemblies to allow for a continuous process.
14. The system of claim 1, wherein at least one of the first caul
plate or the second caul plate further comprises one or more
stiffening ribs to enable handling thereof.
15. The system of claim 14, wherein the one or more stiffening ribs
are positioned outside of the heating and cooling assemblies.
16. The system of claim 1, wherein the support frame further
comprises a plurality of rollers arranged adjacent to the inlet
and/or the outlet of the housing of the heating assembly for
assisting with drawing the one or more layers of material to be
consolidated into and out of the heating assembly.
17. A method for manufacturing a panel, the method comprising:
placing one or more layers of material to be consolidated between
first and second caul plates to form a sandwiched assembly; drawing
the sandwiched assembly through a heating assembly having a housing
and one or more heaters; and, applying pressure and heat to the one
or more layers of material to be consolidated via a first
pressurized gas film generated by the housing and the one or more
heaters of the heating assembly, respectively, thereby
consolidating the panel.
18. The method of claim 17, further comprising: subsequently
cooling the one or more layers of material to be consolidated via a
cooling assembly consecutively aligned with the heating assembly;
and, applying, via the cooling assembly, a second pressurized gas
film to the panel while a chilled air stream is circulated over the
panel.
19. The method of claim 17, wherein applying the pressure and the
heat to the one or more layers of material to be consolidated via
the first pressurized gas film generated by the heating assembly
and the one or more heaters of the heating assembly, respectively,
further comprises applying the pressure and the heat to both sides
of the one or more layers of material to be consolidated.
20. The method of claim 17, further comprising sealing the heating
assembly via one or more sealing members arranged between the
housing and the first and second caul plates.
Description
FIELD
[0001] The present disclosure relates in general to wind turbines,
and more particularly to systems and methods for manufacturing
panels, e.g. that can be used to form wind turbine rotor blade
components.
BACKGROUND
[0002] Wind power is considered one of the cleanest, most
environmentally friendly energy sources presently available, and
wind turbines have gained increased attention in this regard. A
modern wind turbine typically includes a tower, a generator, a
gearbox, a nacelle, and one or more rotor blades. The rotor blades
capture kinetic energy of wind using known foil principles. The
rotor blades transmit the kinetic energy in the form of rotational
energy so as to turn a shaft coupling the rotor blades to a
gearbox, or if a gearbox is not used, directly to the generator.
The generator then converts the mechanical energy to electrical
energy that may be deployed to a utility grid.
[0003] The rotor blades generally include a suction side shell and
a pressure side shell typically formed using molding processes that
are bonded together at bond lines along the leading and trailing
edges of the blade. Further, the pressure and suction shells are
relatively lightweight and have structural properties (e.g.,
stiffness, buckling resistance and strength) which are not
configured to withstand the bending moments and other loads exerted
on the rotor blade during operation. Thus, to increase the
stiffness, buckling resistance and strength of the rotor blade, the
body shell is typically reinforced using one or more exterior
structural components (e.g. opposing spar caps with a shear web
configured therebetween) that engage the inner pressure and suction
side surfaces of the shell halves.
[0004] The spar caps are typically constructed of various
materials, including but not limited to glass fiber laminate
composites and/or carbon fiber laminate composites. The shell of
the rotor blade is generally built around the spar caps of the
blade by stacking layers of fiber fabrics in a shell mold. The
layers are then typically infused together, e.g. with a thermoset
resin. Accordingly, conventional rotor blades generally have a
sandwich panel configuration. As such, conventional blade
manufacturing of large rotor blades involves high labor costs, slow
through put, and low utilization of expensive mold tooling.
Further, the blade molds can be expensive to customize.
[0005] Thus, methods for manufacturing rotor blades may include
forming the rotor blades in segments. The blade segments may then
be assembled to form the rotor blade. For example, some modern
rotor blades, such as those blades described in U.S. patent
application Ser. No. 14/753,137 filed Jun. 29, 2015 and entitled
"Modular Wind Turbine Rotor Blades and Methods of Assembling Same,"
which is incorporated herein by reference in its entirety, have a
modular panel configuration. Thus, the various blade components of
the modular blade can be constructed of varying materials based on
the function and/or location of the blade component.
[0006] The necessary constituents for manufacturing composite
laminates that can be used to construct the blade shells include
temperature, pressure, and consolidation time. Thus, by applying
and optimizing these three factors to a matrix of fibers and resin,
a unified and homogeneous structure can be produced. Due to the
large size of wind turbine rotor blades, however, achieving all
three factors simultaneously can be difficult or cost
prohibitive.
[0007] For example, static mechanical hydraulic/pneumatic presses
are insufficient for manufacturing large composite laminates for at
least two reasons. First, the non-continuous nature of the press
means that the press plates must encompass the entire desired size
of the laminate. With the targeted size and pressure needed for
rotor blades, a machine weighing hundreds of tons would be
required, which is impractical and/or uneconomical to operate. The
entire press plates would be required to thermally cycle between
hot/cold temperatures to consolidate the laminate structure.
Changing the temperature of this amount of mass can be impractical
and/or uneconomical. For example, multiple presses can be employed,
with one being held at a high temperature and another at room
temperature. However, this scenario introduces the possibility of
fibers being distorted as the material is moved between the hot and
cold presses. This scenario also has a very high capital equipment
cost.
[0008] Other options such as double belt presses also exist. For
example, double belt presses use physical contact of continuous
metal belts as a means to transmit pressure and temperature from
the press structure to the laminate. This results in an imperfect
distribution of pressure as the widths are scaled up to very large
sizes. Because of friction present between the heated bushings
sliding over the continuous belt, there is an upper limit of
consolidation pressure due to the tensile strength of the belt. The
length of the hot/cold temperature zone is also limited due to this
friction. This also produces undesirable wear and tear on the
polished continuous metal belts, as well as undesirable effects of
scaling. Polymer double belt presses can overcome some of these
friction problems but suffer from a temperature limitation (greater
than about 250 degrees Celsius (.degree. C.)) due to the belt
material.
[0009] In view of the foregoing, the art is continually seeking
improved systems and methods for manufacturing large flat panels,
such as flat composite laminates that can be used to form wind
turbine rotor blade shells.
BRIEF DESCRIPTION
[0010] Aspects and advantages of the invention will be set forth in
part in the following description, or may be obvious from the
description, or may be learned through practice of the
invention.
[0011] In one aspect, the present disclosure is directed to a
system for manufacturing a panel e.g. that can be used to form a
rotor blade component. The system includes a support frame, a first
caul plate arranged atop the support frame, a second caul plate
arranged atop the first caul plate, and a heating assembly having a
housing defining an inlet and an outlet. The housing includes one
or more heaters. The heater(s) is configured to generate heat and
the housing is configured to generate a first pressurized gas film.
Thus, one or more layers of material to be consolidated may be
placed between the first and second caul plates and drawn through
the heating assembly as the heating assembly applies pressure to
the one or more layers of material to be consolidated via the first
pressurized gas film in combination with applying the heat via the
one or more heaters, thereby consolidating the panel.
[0012] In an embodiment, the system may include a cooling assembly
consecutively aligned with the heating assembly for solidifying the
panel. In such embodiments, the heating assembly may also include
at least one optical window arranged adjacent to the heater(s). As
such, the heat from the heater(s) is configured to pass through the
optical window(s) and heat the layer(s) of material to be
consolidated.
[0013] In another embodiment, the cooling assembly is configured to
apply a second pressurized gas film to the panel while a chilled
air stream is circulated over the panel.
[0014] In further embodiments, the heater(s) may include a
plurality of first heaters and a plurality of second heaters. In
such embodiments, the plurality of first heaters may be arranged
below the first caul plate, whereas the plurality of second heaters
may be arranged above the second caul plate.
[0015] In additional embodiments, the heating assembly may include
one or more sealing members between the housing and the first and
second caul plates. As such, the sealing member(s) may be
configured to provide a sealed environment that can maintain a
desired pressure in the heating assembly. In an embodiment, the
sealing member(s) may include a first sealing ring and a second
sealing ring between the housing and the first and second caul
plates.
[0016] In several embodiments, the sealing member(s) may be
variable height seals. Further, the layer(s) of material to be
consolidated may include one or more fiber and/or resin layers
having a variable thickness. In such embodiments, the variable
height seals are configured to accommodate the variable
thickness.
[0017] In particular embodiments, the heater(s) may include, for
example, radiant heaters or lasers to provide high power
density.
[0018] In another embodiment, the system may include a spool. In
such embodiments, upon cooling, the panel may be separated from the
first and second caul plates and spooled onto the spool. In an
embodiment, the first and second caul plates may be hinged on one
side thereof to facilitate removal of the panel and reinserting
additional layers of material to be consolidated to allow for
repeat processes.
[0019] In further embodiments, the first and second caul plates may
be constructed of steel, titanium, or similar.
[0020] In an embodiment, the first and second caul plates may be
continuous belts that rotate through the heating and cooling
assemblies to allow for a continuous process.
[0021] In still another embodiment, the first and/or second caul
plates may include one or more stiffening ribs to enable handling
thereof. In such embodiments, the stiffening rib(s) may be
positioned outside of the heating and cooling assemblies.
[0022] In yet another embodiment, the support frame may include a
plurality of rollers arranged adjacent to the inlet and/or the
outlet of the housing of the heating assembly for assisting with
drawing the layer(s) of material to be consolidated into and out of
the heating assembly.
[0023] In another aspect, the present disclosure is directed to a
method for manufacturing a panel e.g. that can be used to form of a
rotor blade component. The method includes placing one or more
layers of material to be consolidated between first and second caul
plates to form a sandwiched assembly. The method also includes
drawing the sandwiched assembly through a heating assembly having a
housing and one or more heaters. Further, the method includes
applying pressure and heat to the one or more layers of material to
be consolidated via a first pressurized gas film generated by the
housing and the one or more heaters of the heating assembly,
respectively, thereby consolidating the panel. It should be
understood that the method may further include any of the
additional steps and/or features described herein.
[0024] These and other features, aspects and advantages of the
present invention will become better understood with reference to
the following description and appended claims. The accompanying
drawings, which are incorporated in and constitute a part of this
specification, illustrate embodiments of the invention and,
together with the description, serve to explain the principles of
the invention.
BRIEF DESCRIPTION OF THE DRAWINGS
[0025] A full and enabling disclosure of the present invention,
including the best mode thereof, directed to one of ordinary skill
in the art, is set forth in the specification, which makes
reference to the appended figures, in which:
[0026] FIG. 1 illustrates a perspective view of one embodiment of a
wind turbine according to the present disclosure;
[0027] FIG. 2 illustrates a perspective view of one embodiment of a
rotor blade of a wind turbine according to the present
disclosure;
[0028] FIG. 3 illustrates an exploded view of the modular rotor
blade of FIG. 2;
[0029] FIG. 4 illustrates a cross-sectional view of one embodiment
of a leading edge segment of a modular rotor blade according to the
present disclosure;
[0030] FIG. 5 illustrates a cross-sectional view of one embodiment
of a trailing edge segment of a modular rotor blade according to
the present disclosure;
[0031] FIG. 6 illustrates a cross-sectional view of the modular
rotor blade of FIG. 2 according to the present disclosure;
[0032] FIG. 7 illustrates a cross-sectional view of the modular
rotor blade of FIG. 2 according to the present disclosure;
[0033] FIG. 8 illustrates a perspective view of one embodiment of a
system for manufacturing a panel for a rotor blade component
according to the present disclosure;
[0034] FIG. 9 illustrates a cross-sectional view of a portion of
the system of FIG. 8;
[0035] FIG. 10 illustrates a perspective view of one embodiment of
the caul plates of the system according to the present
disclosure;
[0036] FIG. 11 illustrates a detailed, cross-sectional view of a
portion of the system according to the present disclosure;
[0037] FIG. 12 illustrates a cross-sectional view of one embodiment
of a plurality of fiber and/or resin layers used to form the panel
according to the present disclosure; and
[0038] FIG. 13 illustrates a flow diagram of one embodiment of a
method for manufacturing a panel for a rotor blade component
according to the present disclosure.
DETAILED DESCRIPTION
[0039] Reference now will be made in detail to embodiments of the
invention, one or more examples of which are illustrated in the
drawings. Each example is provided by way of explanation of the
invention, not limitation of the invention. In fact, it will be
apparent to those skilled in the art that various modifications and
variations can be made in the present invention without departing
from the scope or spirit of the invention. For instance, features
illustrated or described as part of one embodiment can be used with
another embodiment to yield a still further embodiment. Thus, it is
intended that the present invention covers such modifications and
variations as come within the scope of the appended claims and
their equivalents.
[0040] Generally, the present disclosure is directed to systems and
methods for manufacturing flat panels, such as large, flat
composite laminate panels. Such panels, for example, may be used in
wind turbine rotor blade applications (e.g. by shaping the flat
panels into curved panels), transportation applications, as well as
any other industry that can benefit from the use of such panels.
Accordingly, in an embodiment, one or more material layers to be
consolidated may be stacked and placed between an upper and lower
caul plate (e.g. steel/titanium/other). This sandwiched assembly
may thus be drawn through a consecutive heating and cooling portal.
In this portal, a pressurized thin gas film may be used in
combination with energy passed through an optical window for
applying pressure and heat to the layers to be consolidated. In
certain instances, this permits the simultaneous application of
temperature (e.g. of at least about 300.degree. C. for
thermoplastics) and pressure (e.g. of from about 30 psi to about
150 psi or any other suitable pressure) to the layers for a desired
period of time (e.g. from about 30 seconds to about 500 seconds).
High energy heaters can radiate heat through the optical window,
which is absorbed by the caul plate/laminate sandwich assembly.
Thus, after a sufficient amount of time, for composite laminate
panels, the resin reaches its melt temperature and a fully wet out
condition and is infused into and among the fiber as it reaches the
cooling portal.
[0041] The panel can then be cooled as quickly as possible, while
maintaining a high pressure to ensure that all voids are minimized.
For example, in an embodiment, a cooling assembly may generate a
second air bearing gas film plate to apply pressure to the laminate
while a chilled air stream is circulated over the panel. Upon
cooling, the panel may be separated from the caul plates and
spooled up. Thus, in an embodiment, the present disclosure allows
the manufacture of large scale panels (e.g. thermoplastic laminate
structures) for wind turbine blade skins at significantly improved
economics and at a size not previously possible using prior art
systems. In addition, the systems and methods of the present
disclosure provide uniform consolidation pressure as compared to
conventional double belt press manufacturing techniques.
[0042] Referring now to the drawings, FIG. 1 illustrates one
embodiment of a wind turbine 10 according to the present
disclosure. As shown, the wind turbine 10 includes a tower 12 with
a nacelle 14 mounted thereon. A plurality of rotor blades 16 are
mounted to a rotor hub 18, which is in turn connected to a main
flange that turns a main rotor shaft. The wind turbine power
generation and control components are housed within the nacelle 14.
The view of FIG. 1 is provided for illustrative purposes only to
place the present invention in an exemplary field of use. It should
be appreciated that the invention is not limited to any particular
type of wind turbine configuration. In addition, the present
invention is not limited to use with wind turbines, but may be
utilized in any application having rotor blades as well as other
applications such as the automotive industry. Further, the methods
described herein may also apply to the manufacturing of any similar
structure that benefits from printing a structure directly to skins
within a mold before the skins have cooled so as to take advantage
of the heat from the skins to provide adequate bonding between the
printed structure and the skins. As such, the need for additional
adhesive or additional curing is eliminated.
[0043] Referring now to FIGS. 2 and 3, various views of a rotor
blade 16 according to the present disclosure are illustrated. As
shown, the illustrated rotor blade 16 has a segmented or modular
configuration. It should also be understood that the rotor blade 16
may include any other suitable configuration now known or later
developed in the art. As shown, the modular rotor blade 16 includes
a main blade structure 15 constructed, at least in part, from a
thermoset and/or a thermoplastic material and at least one blade
segment 21 configured with the main blade structure 15. More
specifically, as shown, the rotor blade 16 includes a plurality of
blade segments 21. The blade segment(s) 21 may also be constructed,
at least in part, from a thermoset and/or a thermoplastic
material.
[0044] The thermoplastic materials as described herein generally
encompass a plastic material or polymer that is reversible in
nature. Further, the thermoplastic materials as described herein
may be in any suitable form such as film, nonwoven, powder, or
similar. For example, thermoplastic materials typically become
pliable or moldable when heated to a certain temperature and
returns to a more rigid state upon cooling. Further, thermoplastic
materials may include amorphous thermoplastic materials and/or
semi-crystalline thermoplastic materials. For example, some
amorphous thermoplastic materials may generally include, but are
not limited to, styrenes, vinyls, cellulosics, polyesters,
acrylics, polysulphones, and/or imides. More specifically,
exemplary amorphous thermoplastic materials may include
polystyrene, acrylonitrile butadiene styrene (ABS), polymethyl
methacrylate (PMMA), glycolised polyethylene terephthalate (PET-G),
polycarbonate, polyvinyl acetate, amorphous polyamide, polyvinyl
chlorides (PVC), polyvinylidene chloride, polyurethane, or any
other suitable amorphous thermoplastic material. In addition,
exemplary semi-crystalline thermoplastic materials may generally
include, but are not limited to polyolefins, polyamides,
fluropolymer, ethyl-methyl acrylate, polyesters, polycarbonates,
and/or acetals. More specifically, exemplary semi-crystalline
thermoplastic materials may include polybutylene terephthalate
(PBT), polyethylene terephthalate (PET), polypropylene, polyphenyl
sulfide, polyethylene, polyamide (nylon), polyetherketone, or any
other suitable semi-crystalline thermoplastic material.
[0045] Further, the thermoset components and/or materials as
described herein generally encompass a plastic material or polymer
that is non-reversible in nature. For example, thermoset materials,
once cured, cannot be easily remolded or returned to a liquid
state. As such, after initial forming, thermoset materials are
generally resistant to heat, corrosion, and/or creep. Example
thermoset materials may generally include, but are not limited to,
some polyesters, some polyurethanes, esters, epoxies, or any other
suitable thermoset material.
[0046] In addition, as mentioned, the thermoplastic and/or the
thermoset material as described herein may optionally be reinforced
with a fiber material, including but not limited to glass fibers,
carbon fibers, basalt fibers, polymer fibers, wood fibers, bamboo
fibers, ceramic fibers, nanofibers, metal fibers, or similar or
combinations thereof. In addition, the direction of the fibers may
include multi-axial, unidirectional, biaxial, triaxial, or any
other another suitable direction and/or combinations thereof.
Further, the fiber content may vary depending on the stiffness
required in the corresponding blade component, the region or
location of the blade component in the rotor blade 16, and/or the
desired weldability of the component.
[0047] More specifically, as shown, the main blade structure 15 may
include any one of or a combination of the following: a pre-formed
blade root section 20, a pre-formed blade tip section 22, one or
more one or more continuous spar caps 48, 50, 51, 53, one or more
shear webs 35 (FIGS. 6-7), an additional structural component 52
secured to the blade root section 20, and/or any other suitable
structural component of the rotor blade 16. Further, the blade root
section 20 is configured to be mounted or otherwise secured to the
rotor 18 (FIG. 1). In addition, as shown in FIG. 2, the rotor blade
16 defines a span 23 that is equal to the total length between the
blade root section 20 and the blade tip section 22. As shown in
FIGS. 2 and 6, the rotor blade 16 also defines a chord 25 that is
equal to the total length between a leading edge 24 of the rotor
blade 16 and a trailing edge 26 of the rotor blade 16. As is
generally understood, the chord 25 may generally vary in length
with respect to the span 23 as the rotor blade 16 extends from the
blade root section 20 to the blade tip section 22.
[0048] Referring particularly to FIGS. 2-4, any number of blade
segments 21 or panels (also referred to herein as blade shells)
having any suitable size and/or shape may be generally arranged
between the blade root section 20 and the blade tip section 22
along a longitudinal axis 27 in a generally span-wise direction.
Thus, the blade segments 21 generally serve as the outer
casing/covering of the rotor blade 16 and may define a
substantially aerodynamic profile, such as by defining a
symmetrical or cambered airfoil-shaped cross-section. In additional
embodiments, it should be understood that the blade segment portion
of the blade 16 may include any combination of the segments
described herein and are not limited to the embodiment as depicted.
In addition, the blade segments 21 may be constructed of any
suitable materials, including but not limited to a thermoset
material or a thermoplastic material optionally reinforced with one
or more fiber materials. More specifically, in certain embodiments,
the blade segments 21 may include any one of or combination of the
following: pressure and/or suction side segments 44, 46, (FIGS. 2
and 3), leading and/or trailing edge segments 40, 42 (FIGS. 2-6), a
non-jointed segment, a single-jointed segment, a multi jointed
blade segment, a J-shaped blade segment, or similar.
[0049] More specifically, as shown in FIG. 4, the leading edge
segments 40 may have a forward pressure side surface 28 and a
forward suction side surface 30. Similarly, as shown in FIG. 5,
each of the trailing edge segments 42 may have an aft pressure side
surface 32 and an aft suction side surface 34. Thus, the forward
pressure side surface 28 of the leading edge segment 40 and the aft
pressure side surface 32 of the trailing edge segment 42 generally
define a pressure side surface of the rotor blade 16. Similarly,
the forward suction side surface 30 of the leading edge segment 40
and the aft suction side surface 34 of the trailing edge segment 42
generally define a suction side surface of the rotor blade 16. In
addition, as particularly shown in FIG. 6, the leading edge
segment(s) 40 and the trailing edge segment(s) 42 may be joined at
a pressure side seam 36 and a suction side seam 38. For example,
the blade segments 40, 42 may be configured to overlap at the
pressure side seam 36 and/or the suction side seam 38. Further, as
shown in FIG. 2, adjacent blade segments 21 may be configured to
overlap at a seam 54. Thus, where the blade segments 21 are
constructed at least partially of a thermoplastic material,
adjacent blade segments 21 can be welded together along the seams
36, 38, 54, which will be discussed in more detail herein.
Alternatively, in certain embodiments, the various segments of the
rotor blade 16 may be secured together via an adhesive (or
mechanical fasteners) configured between the overlapping leading
and trailing edge segments 40, 42 and/or the overlapping adjacent
leading or trailing edge segments 40, 42.
[0050] In specific embodiments, as shown in FIGS. 2-3 and 6-7, the
blade root section 20 may include one or more longitudinally
extending spar caps 48, 50 infused therewith. For example, the
blade root section 20 may be configured according to U.S.
application Ser. No. 14/753,155 filed Jun. 29, 2015 entitled "Blade
Root Section for a Modular Rotor Blade and Method of Manufacturing
Same" which is incorporated herein by reference in its
entirety.
[0051] Similarly, the blade tip section 22 may include one or more
longitudinally extending spar caps 51, 53 infused therewith. More
specifically, as shown, the spar caps 48, 50, 51, 53 may be
configured to be engaged against opposing inner surfaces of the
blade segments 21 of the rotor blade 16. Further, the blade root
spar caps 48, 50 may be configured to align with the blade tip spar
caps 51, 53. Thus, the spar caps 48, 50, 51, 53 may generally be
designed to control the bending stresses and/or other loads acting
on the rotor blade 16 in a generally span-wise direction (a
direction parallel to the span 23 of the rotor blade 16) during
operation of a wind turbine 10. In addition, the spar caps 48, 50,
51, 53 may be designed to withstand the span-wise compression
occurring during operation of the wind turbine 10. Further, the
spar cap(s) 48, 50, 51, 53 may be configured to extend from the
blade root section 20 to the blade tip section 22 or a portion
thereof. Thus, in certain embodiments, the blade root section 20
and the blade tip section 22 may be joined together via their
respective spar caps 48, 50, 51, 53.
[0052] In addition, the spar caps 48, 50, 51, 53 may be constructed
of any suitable materials, e.g. a thermoplastic or thermoset
material or combinations thereof. Further, the spar caps 48, 50,
51, 53 may be pultruded from thermoplastic or thermoset resins. As
used herein, the terms "pultruded," "pultrusions," or similar
generally encompass reinforced materials (e.g. fibers or woven or
braided strands) that are impregnated with a resin and pulled
through a stationary die such that the resin cures or undergoes
polymerization. As such, the process of manufacturing pultruded
members is typically characterized by a continuous process of
composite materials that produces composite parts having a constant
cross-section. Thus, the pre-cured composite materials may include
pultrusions constructed of reinforced thermoset or thermoplastic
materials. Further, the spar caps 48, 50, 51, 53 may be formed of
the same pre-cured composites or different pre-cured composites. In
addition, the pultruded components may be produced from rovings,
which generally encompass long and narrow bundles of fibers that
are not combined until joined by a cured resin.
[0053] Referring to FIGS. 6-7, one or more shear webs 35 may be
configured between the one or more spar caps 48, 50, 51, 53. More
particularly, the shear web(s) 35 may be configured to increase the
rigidity in the blade root section 20 and/or the blade tip section
22. Further, the shear web(s) 35 may be configured to close out the
blade root section 20.
[0054] In addition, as shown in FIGS. 2 and 3, the additional
structural component 52 may be secured to the blade root section 20
and extend in a generally span-wise direction so as to provide
further support to the rotor blade 16. For example, the structural
component 52 may be configured according to U.S. application Ser.
No. 14/753,150 filed Jun. 29, 2015 entitled "Structural Component
for a Modular Rotor Blade" which is incorporated herein by
reference in its entirety. More specifically, the structural
component 52 may extend any suitable distance between the blade
root section 20 and the blade tip section 22. Thus, the structural
component 52 is configured to provide additional structural support
for the rotor blade 16 as well as an optional mounting structure
for the various blade segments 21 as described herein. For example,
in certain embodiments, the structural component 52 may be secured
to the blade root section 20 and may extend a predetermined
span-wise distance such that the leading and/or trailing edge
segments 40, 42 can be mounted thereto.
[0055] Referring now to FIGS. 8-13, the present disclosure is
directed to systems and method for manufacturing a panel that can
be used in various wind turbine components, such as the rotor blade
shell described herein. For example, as shown in FIG. 8, a
perspective view of one embodiment of a system 100 for
manufacturing a panel for a rotor blade component is illustrated.
FIG. 9 illustrates a cross-sectional view of a portion of the
system 100 of FIG. 8. FIG. 10 illustrates a perspective view of one
embodiment of the caul plates of the system 100 according to the
present disclosure. FIG. 11 illustrates a detailed, cross-sectional
view of a portion of the system 100 according to the present
disclosure. FIG. 12 illustrates a cross-sectional view of one
embodiment of a plurality of material layers 110 to be consolidated
used to form the panel 130 described herein.
[0056] As shown in FIG. 8, the system 100 includes a support frame
102 for supporting the panel (not shown) as the panel is being made
as well as supporting the heating 112 and cooling 114 assemblies of
the system 100. Thus, as shown, the support frame 102 may have a
table-like configuration with legs 104 and a support surface 106.
Further, as shown, the support frame 102 may include a plurality of
rollers 108 at one or more ends thereof so as to assist with
drawing the layer(s) of material 110 to be consolidated into and
out of the heating and cooling assemblies 112 and 114,
respectively.
[0057] Referring now to FIG. 9, a cross-sectional view of a portion
of the system 100 of FIG. 8 is illustrated, particularly
illustrating the layer(s) of material 110 to be consolidated being
drawing into the heating assembly 112. More specifically, as shown,
the layer(s) of material 110 to be consolidated may include one or
more fiber and/or resin layers 110 that can be sandwiched between a
first caul plate 122 and a second caul plate 124. Thus, as shown,
the first caul plate 122 is supported directly atop the support
frame 102, whereas the second caul plate 124 is supported atop the
first caul plate 122 and the layer(s) 110. In certain embodiments,
the first and second caul plates 122, 124 may be constructed of
steel, titanium, or similar.
[0058] In an embodiment, as shown in FIG. 9, the first and second
caul plates 122, 124 may be continuous belts that rotate through
the heating and cooling assemblies 112, 114 to allow for a
continuous process. In another embodiment, as shown in FIG. 10, the
first and/or second caul plates 122, 124 may include one or more
stiffening ribs 144, 146, e.g. on an outer edge thereof to enable
handling thereof. It should be understood that the stiffening ribs
144, 146 may include any suitable rib, protrusion, handle, or
similar. In such embodiments, the stiffening rib(s) 144, 146 may be
positioned outside of the heating and cooling assemblies 112, 114,
e.g. when passing therethrough.
[0059] Further, as shown in FIG. 9, the heating assembly 112 may
have a housing 116 defining an inlet 118 and an outlet 120. Thus,
as shown, the housing 116 includes one or more heaters 125, 126
configured to generate heat, e.g. that can pass through at least
one optical window 128. For example, as shown, the heater(s) 125,
126 may include a plurality of first heaters 125 and a plurality of
second heaters 126. In such embodiments, the plurality of first
heaters 125 may be arranged below the first caul plate 122, whereas
the plurality of second heaters 126 may be arranged above the
second caul plate 124. In particular embodiments, the heater(s)
125, 126 may include any suitable heater type, such as, for
example, radiant heaters or lasers. In such embodiments, where
radiant heaters are used, the heat from the heater(s) 125, 126
radiates through the optical window 128 and is absorbed by the
first and second caul plates 122, 124 so as to heat the material
layer(s) 110. Therefore, the heaters 125, 126 described herein may
be non-contact heaters (i.e. the heaters 125, 126 do not contact
the layer(s) of material 110 to be consolidated during heating
thereof).
[0060] By physically separating the heaters 125, 126 from the
material/caul plate structure, very high temperature heater
elements (e.g. from about 400.degree. C. to about 1200.degree. C.)
can be used. This high gradient allows for a more efficient
transfer of energy than would otherwise be possible. The
frictionless nature of the heaters 125, 126 also allows the
continuous free travel of the caul plates 122, 124 through the
heating and cooling assemblies 112, 114. The non-contacting heaters
125, 126, therefore, provide an advantage over other conventional
systems that would require releasing the pressure before indexing
the caul plate to a new location.
[0061] In addition, the heating assembly 112 may also include one
or more sealing members 134, 136 arranged between the housing and
the first and second caul plates 116. In an embodiment, as shown,
the sealing member(s) 134, 136 may include a first sealing ring 134
and a second sealing ring 136. Thus, the sealing rings 134, 136 are
configured to create a sealed environment between the housing and
the first and second caul plates 122, 124 so as to provide
pressurized gas (such as air) therebetween. Accordingly, one or
more air bearings (also referred to herein as pressurized gas
films) may be used to apply pressure to the resin/caul plate
structure. Therefore, in such embodiments, the use of a
frictionless air bearing in combination with the radiant heaters
125, 126 allows for decoupling of pressure, heat, and time.
[0062] Thus, in certain embodiments, the layer(s) of material 110
to be consolidated 110 placed between the first and second caul
plates 122, 124 can be drawn at any suitable speed, e.g. such as a
constant speed, through the heating assembly 112. Accordingly, the
heating assembly 112 is configured to generate and apply pressure
to the layer(s) of material 110 to be consolidated via a first
pressurized gas film 132 in combination with applying the heat that
passes through the optical window(s) 128, thereby forming the panel
130. In an embodiment, the heat and the pressure may be applied
simultaneously. Because the pressure is applied over a large
surface area (e.g. instead of a line contact), the period of time
that the panel experiences a compaction force is increased from a
few milliseconds (e.g. when using pinch roller systems) to a period
of many seconds dependent upon the processing speed of the layer(s)
of material 110 to be consolidated. This order of magnitude
increase dramatically increases laminate quality and resin melt wet
out of the panel 130.
[0063] Referring back to FIG. 8, the system 100 may also include a
cooling assembly 114 consecutively aligned with the heating
assembly 112. In such embodiments, wherein the layer(s) of material
110 to be consolidated includes fibers and resin, the heat that
passes through the optical window(s) 128 is configured to heat the
resin to its melting temperature such that the resin is infused
into the fiber thereof as the layer(s) of material 110 to be
consolidated reaches the cooling assembly 114. In another
embodiment, as shown in FIG. 9, the cooling assembly 114 is
configured to apply a second pressurized gas film 148 to the panel
130 while a chilled air stream 150 is circulated over the panel
130.
[0064] In several embodiments, as shown in FIG. 12, the layer(s) of
material 110 to be consolidated may include a plurality of fiber
and/or resin layers 138 having a variable thickness (as represented
by T.sub.1, T.sub.2, and T.sub.3). In such embodiments, the first
and second pressurized gas films 132, 148 are configured to
accommodate the variable thicknesses T.sub.1, T.sub.2, and T.sub.3.
In other words, the first and second pressurized gas films 132, 148
(isobaric instead of isochoric), allows some flexibility to use ply
drops within the panel 130 as the system 100 can accommodate minor
thickness changes which typical isochoric belt presses cannot. In
addition, in certain embodiments, the first and second pressurized
gas films 132, 148 can be adjusted. In such embodiments, as shown
particularly in FIG. 11, the sealing members 134, 136 may be
variable height seals. For example, as shown, the height of the
sealing members 134, 136 may be varied via one or more springs 135.
As such, the variable height seals may be employed to maintain an
airtight seal over panels 130 of variable thickness.
[0065] In another embodiment, as shown in FIG. 9, the system 100
may include a spool 140. In such embodiments, upon cooling, the
panel 130 may be separated from the first and second caul plates
122, 124 and spooled onto the spool 140, e.g. for storage. In
addition, in an embodiment, as shown in FIG. 10, the first and
second caul plates 122, 124 may be hinged (e.g. via hinge 142) on
one side thereof to facilitate removal of the panel 130 and
reinserting one or more additional materials to be consolidated for
repeat processes.
[0066] Referring now to FIG. 13, the present disclosure is directed
to methods for manufacturing a panel, e.g. for a rotor blade shell
and/or blade add-ons. More specifically, as shown, a flow diagram
of one embodiment of a method 200 for manufacturing a panel is
illustrated. As such, in certain embodiments, the rotor blade shell
21 may define a pressure side shell, a suction side shell, a
trailing edge segment, a leading edge segment, or combinations
thereof. In general, the method 200 is described herein as
implemented for manufacturing panels used in forming the rotor
blade shells 21 described above. However, it should be appreciated
that the disclosed method 200 may be used to manufacture any other
panel. In addition, although FIG. 13 depicts steps performed in a
particular order for purposes of illustration and discussion, the
methods described herein are not limited to any particular order or
arrangement. One skilled in the art, using the disclosures provided
herein, will appreciate that various steps of the methods can be
omitted, rearranged, combined and/or adapted in various ways.
[0067] As shown at (202), the method 200 includes placing one or
more layer(s) of material 110 to be consolidated between first and
second caul plates 122, 124 to form a sandwiched assembly. As shown
at (204), the method 200 includes drawing the sandwiched assembly
through the heating assembly 112 having a housing and one or more
heaters. As shown at (206), the method 20 includes applying
pressure and heat to the one or more layers 110 of material to be
consolidated via a first pressurized gas film generated by the
housing and the one or more heaters of the heating assembly 112,
respectively, thereby consolidating the panel 130.
[0068] The method 200 may also include subsequently cooling the
layer(s) of material 110 to be consolidated via a cooling assembly
114 consecutively aligned with the heating assembly 112 and
applying, via the cooling assembly 114, a second pressurized gas
film 148 to the panel 130 while a chilled air stream is circulated
over the panel 130.
[0069] In another embodiment, simultaneously applying the pressure
and the heat to the layer(s) of material 110 to be consolidated via
the first pressurized gas film 132 and the heating assembly 112,
respectively, may include applying the pressure and the heat to
both sides of the layer(s) of material 110 to be consolidated. In
further embodiments, the method 200 may include sealing the heating
assembly 112 via one or more sealing members 134, 136 arranged
between the housing 116 and the first and second caul plates 122,
124.
[0070] Various aspects and embodiments of the present invention are
defined by the following numbered clauses:
[0071] Clause 1. A system for manufacturing a panel, the system
comprising:
[0072] a support frame;
[0073] a first caul plate arranged atop the support frame;
[0074] a second caul plate arranged atop the first caul plate;
and,
[0075] a heating assembly comprising a housing defining an inlet
and an outlet, the housing comprising one or more heaters, the one
or more heaters configured to generate heat, the housing configured
to generate a first pressurized gas film;
[0076] wherein one or more layers of material to be consolidated is
placed between the first and second caul plates and drawn through
the heating assembly as the heating assembly applies pressure to
the one or more layers of material to be consolidated via the first
pressurized gas film in combination with applying heat via the one
or more heaters, thereby consolidating the panel.
[0077] Clause 2. The system of Clause 1, further comprising a
cooling assembly consecutively aligned with the heating assembly
for solidifying the panel.
[0078] Clause 3. The system of Clause 2, wherein the heating
assembly further comprises at least one optical window arranged
adjacent to the one or more heaters, the heat from the one or more
heaters passing through the at least one optical window and heating
the one or more layers of material to be consolidated.
[0079] Clause 4. The system of Clause 2, wherein the cooling
assembly is configured to apply a second pressurized gas film to
the panel while a chilled air stream is circulated over the
panel.
[0080] Clause 5. The system of any of the preceding Clauses,
wherein the one or more heaters further comprises a plurality of
first heaters and a plurality of second heaters, the plurality of
first heaters arranged below the first caul plate, the plurality of
second heaters arranged above the second caul plate.
[0081] Clause 6. The system of any of the preceding Clauses,
wherein the heating assembly further comprises one or more sealing
members between the housing and the first and second caul plates,
the one or more sealing members providing a sealed environment that
maintains a desired pressure between the housing and the first and
second caul plates.
[0082] Clause 7. The system of Clause 6, wherein the one or more
sealing members comprise a first sealing ring and a second sealing
ring between the housing and the first and second caul plates.
[0083] Clause 8. The system of Clause 6, wherein the one or more
sealing members comprise variable height seals, wherein the one or
more layers of material to be consolidated further comprises one or
more fiber and/or resin layers having a variable thickness, the
variable height seals accommodating the variable thickness.
[0084] Clause 9. The system of Clause 2, wherein the one or more
heaters comprise at least one of radiant heaters or lasers.
[0085] Clause 10. The system of any of the preceding Clauses,
further comprising a spool, wherein, upon cooling, the panel is
separated from the first and second caul plates and spooled onto
the spool.
[0086] Clause 11. The system of Clause 10, wherein the first and
second caul plates are hinged on one side thereof to facilitate
removal of the panel and reinserting one or more additional layers
of material to be consolidated layers to for repeat processes.
[0087] Clause 12. The system of any of the preceding Clauses,
wherein the first and second caul plates are constructed of at
least one of steel or titanium.
[0088] Clause 13. The system of Clause 2, wherein the first and
second caul plates are continuous belts that rotate through the
heating and cooling assemblies to allow for a continuous
process.
[0089] Clause 14. The system any of the preceding Clauses, wherein
at least one of the first caul plate or the second caul plate
further comprises one or more stiffening ribs to enable handling
thereof.
[0090] Clause 15. The system of Clause 14, wherein the one or more
stiffening ribs are positioned outside of the heating and cooling
assemblies.
[0091] Clause 16. The system of any of the preceding Clauses,
wherein the support frame further comprises a plurality of rollers
arranged adjacent to the inlet and/or the outlet of the housing of
the heating assembly for assisting with drawing the one or more
layers of material to be consolidated into and out of the heating
assembly.
[0092] Clause 17. A method for manufacturing a panel, the method
comprising:
[0093] placing one or more layers of material to be consolidated
between first and second caul plates to form a sandwiched
assembly;
[0094] drawing the sandwiched assembly through a heating assembly
having a housing and one or more heaters; and
[0095] applying pressure and heat to the one or more layers of
material to be consolidated via a first pressurized gas film
generated by the housing and the one or more heaters of the heating
assembly, respectively, thereby consolidating the panel.
[0096] Clause 18. The method of Clause 17, further comprising:
[0097] subsequently cooling the one or more layers of material to
be consolidated via a cooling assembly consecutively aligned with
the heating assembly; and,
[0098] applying, via the cooling assembly, a second pressurized gas
film to the panel while a chilled air stream is circulated over the
panel.
[0099] Clause 19. The method of Clauses 17-18, wherein applying the
pressure and the heat to the one or more layers of material to be
consolidated via the first pressurized gas film generated by the
heating assembly and the one or more heaters of the heating
assembly, respectively, further comprises applying the pressure and
the heat to both sides of the one or more layers of material to be
consolidated.
[0100] Clause 20. The method of Clauses 17-19, further comprising
sealing the heating assembly via one or more sealing members
arranged between the housing and the first and second caul
plates.
[0101] This written description uses examples to disclose the
invention, including the best mode, and also to enable any person
skilled in the art to practice the invention, including making and
using any devices or systems and performing any incorporated
methods. The patentable scope of the invention is defined by the
claims, and may include other examples that occur to those skilled
in the art. Such other examples are intended to be within the scope
of the claims if they include structural elements that do not
differ from the literal language of the claims, or if they include
equivalent structural elements with insubstantial differences from
the literal languages of the claims.
* * * * *